Electric Motor State Assembly Line

Reduced Cycle Time By 6%

Quality Loss Reduction

Problem Statement

A multi-spot welding station was not meeting the target JPH.

Case Drilldown:

Station’s cycle histogram showed distinct clusters. The anomalous clusters correspond to reworks which have a high frequency, contributing to a higher cycle time.

70% of cycles do not have any rework activities. The remaining 30% contribute to time loss

Both spots fully welded

One spot OK and second spot bypassed/rework to operator

Both spots bypassed/rework to operator

Result

This RCA done for high cycle time gave actionable inputs to update the product design and make it amenable for automation.

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